Splash-resistant lids, container assemblies including such lids and related methods

ABSTRACT

In some embodiments, a lid may include a valve chamber comprising a hollow chamber, a valve flap and a hinge. The hollow chamber may be defined by one or more sidewalls and have a first opening at a first longitudinal end and a second opening at an opposing, second longitudinal end. The valve flap may be positioned at least proximate to the second longitudinal end and have a shape and size substantially the same as a shape and size of the second opening. The hinge may couple the valve flap to a sidewall of the one or more sidewalls and may be sized and configured to enable the rotation of the valve flap from an open position to a substantially closed position. Container assemblies and methods of forming lids are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/762,189, filed Apr. 16, 2010, which will issue as U.S. Pat. No.8,727,163 on May 20, 2014, which application claims the benefit of U.S.Provisional Application No. 61/169,811, filed Apr. 16, 2009, thedisclosures of which are incorporated herein, in their entirety, by thisreference.

TECHNICAL FIELD

Embodiments of the present disclosure relate to lids for beveragecontainers and beverage container assemblies including such lids.

BACKGROUND

Fast food restaurants, coffee shops, convenience stores, and the like,often distribute beverages in disposable drinking cups. These cups areoften provided with drink-through lids having reversible openings, whichpermit the consumption of liquids contained therein, while at the sametime preventing unwanted spillage. Drink-through lids with reversibleopenings are especially desirable when distributing hot beverages, suchas coffee, tea, hot chocolate, and the like.

Various drink-through lid designs incorporating reversible openingsconventionally comprise a lid having a drinking opening and a hingedclosure member integrally formed therewith. According to at least oneexample, the hinged closure member has a radial dimension greater thanthat of the drinking opening to permit an outward marginal edge portionof the hinged closure member to be trapped between the rim of thedrinking cup and an overlying part of the lid. The hinged closure memberfurther includes a raised tab that is received in a complementary recessformed in the lid, when the hinged closure member is rotated outwardone-hundred-eighty degrees (180°) about its integral hinge to expose thedrinking opening. However, a user must manually move the hinged closuremember each time the user wishes to open or close the opening.

Other cup lid designs incorporate reversible openings providing adownwardly depressible tab portion. According to at least one example ofsuch a lid design, the tab portion includes a hollow lip-engagingcorrugated buttress to insulatively engage a user's upper lip pressedthereagainst. The buttress also acts to bias the tab portion back intoits normally closed position, within a horizontal plane of the lid, whenlip pressure is removed therefrom.

BRIEF SUMMARY

In some embodiments, a lid may include a valve chamber comprising ahollow chamber, a valve flap and a hinge. The hollow chamber may bedefined by one or more sidewalls and have a first opening at a firstlongitudinal end and a second opening at an opposing, secondlongitudinal end. The valve flap may be positioned at least proximate tothe second longitudinal end and have a shape and size substantially thesame as a shape and size of the second opening. The hinge may couple thevalve flap to a sidewall of the one or more sidewalls and may be sizedand configured to enable the rotation of the valve flap from an openposition to a substantially closed position. Additionally, the hinge maybias the valve flap to the substantially closed position, wherein thevalve flap inhibits the flow of liquid through the second opening in thesubstantially closed position.

In additional embodiments, a container assembly may include a containerconfigured to hold a liquid therein and a lid. The lid may include avalve chamber comprising a hollow chamber, a valve flap and a hinge. Thehollow chamber may be defined by one or more sidewalls and have a firstopening at a first longitudinal end and a second opening at an opposing,second longitudinal end. The valve flap may be positioned at leastproximate to the second longitudinal end and have a shape and sizesubstantially the same as a shape and size of the second opening. Thehinge may couple the valve flap to a sidewall of the one or moresidewalls and may be sized and configured to enable the rotation of thevalve flap from an open position to a substantially closed position.Additionally, the hinge may bias the valve flap to the substantiallyclosed position, wherein the valve flap inhibits the flow of liquidthrough the second opening in the substantially closed position.

In further embodiments, a method of forming a lid may include forming achannel to engage and seal around a rim of a container. The method mayfurther include forming a valve chamber, the valve chamber comprising ahollow chamber, a valve flap and a hinge. The hollow chamber may bedefined by one or more sidewalls and have a first opening at a firstlongitudinal end and a second opening at an opposing, secondlongitudinal end. The valve flap may be positioned at least proximate tothe second longitudinal end and have a shape and size substantially thesame as a shape and size of the second opening. The hinge may couple thevalve flap to a sidewall of the one or more sidewalls and may be sizedand configured to enable the rotation of the valve flap from an openposition to a substantially closed position. Additionally, the hinge maybias the valve flap to the substantially closed position, wherein thevalve flap inhibits the flow of liquid through the second opening in thesubstantially closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial cross-sectional view of a beverage containerassembly including a container and a lid, according to an embodiment ofthe invention.

FIG. 2 is a top detail view of a valve chamber of the lid shown in FIG.1.

FIG. 3 is a front detail view of the valve chamber of FIG. 2.

FIG. 4 is a side detail view of the valve chamber of FIG. 2.

FIG. 5 illustrates the beverage container assembly of FIG. 1 in use by auser drinking a fluid through the lid.

FIG. 6 is a detail view of a valve chamber of the lid of FIG. 5 showinga valve in an open position and fluid flowing therethrough.

FIG. 7 is a detail view of the valve chamber of the lid of FIG. 5showing the valve in a closed position and a fluid in the valve chamberdraining from the valve chamber into a container.

FIG. 8 is a detail view of the valve chamber of the lid of FIG. 5showing the valve in a closed position and with a fluid splashing in theinside of the container.

FIG. 9 is a partial cross-sectional view of a beverage containerassembly including a container and a lid, according to anotherembodiment of the invention.

FIG. 10 is a top detail view of a valve chamber of the lid shown in FIG.9.

FIG. 11 is a front detail view of the valve chamber of FIG. 10.

FIG. 12 is a side detail view of the valve chamber of FIG. 10.

FIG. 13 illustrates the beverage container assembly of FIG. 9 in use bya user drinking a fluid through the lid.

FIG. 14 is a detail view of the valve chamber of the lid of FIG. 13showing a valve in an open position and fluid flowing therethrough.

FIG. 15 is a detail view of the valve chamber of the lid of FIG. 13showing the valve in a closed position and a fluid in the valve chamberdraining from the valve chamber into the container.

FIG. 16 is a detail view of the valve chamber of the lid of FIG. 13showing the valve in a closed position and with a fluid splashing in theinside of the container.

FIG. 17 is a cross-sectional view of lids, such as shown in FIG. 9, in astacked and nested configuration.

DETAILED DESCRIPTION

The illustrations presented herein are not actual views of anyparticular lids or beverage container and lid assemblies, but are merelyidealized representations that are employed to describe embodiments ofthe present invention. Additionally, elements common between figures mayretain the same numerical designation.

As shown in partial cross-sectional views in FIGS. 1 and 9, a beveragecontainer assembly 100 may include a container 110, such as a cup,having an opening configured to receive a lid 120. Containers 110 arewell known to those of ordinary skill in the art and variousconventional disposable or reusable containers may be employed. By wayof example and not limitation, the container 110 may comprise aconventional disposable coffee cup, insulated or not insulated, aconventional disposable soft-drink cup, such as those used in mostfast-food restaurants, or another beverage container.

The lid 120 may be configured to receive a portion of the container 110and to at least substantially enclose the opening of the container 110.For example, the lid 120 may include a channel 130 configured to engagea rim of the container 110 to form a seal around the opening of thecontainer 110, as is known to those of ordinary skill in the art. Thelid may also include a spout with a valve, which may also becharacterized as a valve chamber 140.

As illustrated in FIGS. 2-4 and 10-12, the valve chamber 140 maycomprise a hollow chamber having an opening 150 at first longitudinalend 160 thereof (i.e., a top end) and a valve flap 180 at an opposing,second longitudinal end 170 (i.e., a bottom end). The valve chamber 140may be defined by one or more sidewalls that extend downward from theopening 150 (i.e., from an upper surface of the lid 120). The valvechamber 140 may be configured such that the first longitudinal end 160may be relatively larger than the second longitudinal end 170.Additionally, the sidewalls of the valve chamber 140 may be sloped at anangle of between about 1° and about 10° relative to vertical (i.e.,vertical with respect to an orientation of the lid coupled to a cupresting on a level surface) (e.g., having and angle between about 2° andabout 20° relative to an opposing sidewall). In other words, thesidewalls may define a hollow chamber that is tapered from the firstlongitudinal end 160 to the second longitudinal end 170. By way ofexample and not limitation, the sidewalls of the valve chamber 140 maybe sloped at an angle of about 5° from vertical (e.g., about 10°relative to an opposing sidewall). The valve chamber 140 may compriseany suitable shape conducive to the flow of a fluid therethrough. By wayof example and not limitation, the valve chamber 140 may comprise across-section that is substantially circular, square, rectangular, oval,etc. Additionally, the valve chamber 140 may comprise a height 210, awidth 220 and a depth 230 which may be selected according to thespecific application. As a non-limiting example, the valve chamber 140may comprise a height 210 of about ⅜ of an inch (about 9.5 mm), a width220 of about ⅜ of an inch (about 9.5 mm), and a depth of about 3/16 ofan inch (about 4.8 mm), such as shown in FIGS. 2-4. As anothernon-limiting example, the valve chamber 140 may comprise a height 210 ofabout 3/16 of an inch (about 4.8 mm), a width 220 of about ⅜ of an inch(about 9.5 mm), and a depth of about ¼ of an inch (about 6.4 mm), suchas shown in FIGS. 10-12.

The valve flap 180 may be positioned at, or at least proximate to, thesecond longitudinal end 170 of the valve chamber 140 and comprise, atleast substantially, the same size and shape as an opening at the secondlongitudinal end 170 of the valve chamber 140. The valve flap 180 may becoupled to a portion of a sidewall of the valve chamber 140 along atleast a portion of one side of the valve flap 180. The remaining sidesof the valve flap 180 may be free from the sidewalls of the valvechamber 140. In view of this, the side of the valve flap 180 coupled tothe sidewall of the valve chamber 140 may form a hinge 190 (which has ageneral location indicated by a dashed line) configured to enable thevalve flap 180 to rotate between a substantially closed position (asshown in FIGS. 1-4, 7-12 and 15-17) and an open position (as shown inFIGS. 5, 6, 13 and 14).

Although the hinge 190 may be a single portion of the side of the valveflap 180 coupled to the sidewall of the valve chamber 140, as shown, inadditional embodiments, the hinge 190 may be comprised of a plurality ofportions of the side of the valve flap 180 coupled to the sidewall ofthe valve chamber 140. The hinge 190 is configured to enable the valveflap 180 to move about the hinge 190. In at least some embodiments, thevalve flap 180 may be integrally formed with the lid 120. Additionally,the structure and geometry of the hinge 190 may be configured to biasthe valve flap 180 to the substantially closed position.

In some embodiments, as shown in FIGS. 2-8, the valve chamber 140 mayinclude a discrete drain 200 positioned at least proximate to the secondlongitudinal end 170. The drain 200 may comprise one or more aperturesand/or notches disposed in a portion of the valve flap 180, a sidewallof the valve chamber 140 or both. As shown in FIGS. 2-4, the drain 200may comprise an aperture defined by a notch formed in the valve flap 180and a corresponding notch formed in a sidewall of the valve chamber 140,the notches being aligned to form the aperture. In some embodiments, thevalve chamber 140 may comprise only a single drain 200, while in otherembodiments the valve chamber 140 may comprise a plurality of drains200.

In additional embodiments, as shown in FIGS. 9-17, the valve flap 180may not form a complete fluid seal with the opening at the secondlongitudinal end 170 of the valve chamber 140 when the valve flap 180 isin the substantially closed position. In view of this, the drain 200 maybe defined by a slit-like opening between the valve flap 180 and theopening in the second longitudinal end 170 of the valve chamber 140 whenthe valve flap 180 is biased to the substantially closed position, asshown in FIGS. 10-12.

In some embodiments, such as shown in FIGS. 1-4, 7 and 8, the valve flap180 may be angled with respect to the horizontal (i.e., horizontal to anintended position when the lid is coupled to a cup and the cup is set ona level surface) when in the substantially closed position, with thedrain 200 positioned in a portion of the valve flap 180, or near thevalve flap 180, at a lowest side, to direct the fluid toward the drain200. By way of example and not limitation, the valve flap 180 may besloped from the hinge 190 downward at an angle between about 1° and 10°relative to horizontal, with the drain 200 positioned proximate the sideof the valve flap 180 opposite the hinge 190, when the valve flap 180 isbiased to the substantially closed position. In at least someembodiments, the valve flap 180 may be sloped downward from the hinge190 at an angle between about 5° and 7° relative to horizontal, when thevalve flap 180 is biased to the substantially closed position. Inadditional embodiments, such as shown in FIGS. 9-12 and 15-17, the valveflap 18 may not be sloped relative to horizontal when biased to thesubstantially closed position. In view of the foregoing, the drain 200may allow liquid inside the valve chamber 140 to flow back into thecontainer 110 through the drain 200.

Additionally, the lid 120 may be shaped and configured to be stacked ina nested configuration. For example, multiple lids 120 may be stackedwith the valve chambers 140 thereof aligned in a nesting configuration,such that a valve chamber of a first lid 120 may be positioned partiallywithin a valve chamber of a second lid 120 when nested, as shown in FIG.17. In view of this, a plurality of lids 120 including valve chambers140 may be stacked and nested for storage, shipping and for dispensingfrom conventional disposable lid dispensers.

In operation, the lid 120 and valve chamber 140 may enable the flow of aliquid from the container 110 to a user's mouth, while inhibiting theflow of the liquid through the valve chamber 140 when the user is notdrinking from the container 110. FIGS. 5 and 13 illustrate a container110 with a lid 120 in operation as a user drinks a liquid from thecontainer 110 and FIGS. 6 and 14 illustrate detail views of embodimentsof the valve chamber 140, when a user drinks from the container 110.

For example, a user may place their mouth over the valve chamber 140 andapply suction to the opening 150 at the first longitudinal end 160 ofthe valve chamber 140. In view of this, the user may create a pressuredifference between the inside of the user's mouth and the interior ofthe container 110. The pressure difference caused by the suction mayresult in the valve flap 180 moving upward into the valve chamber 140,rotating about the hinge 190, to the open position. With the valve flap180 rotated upward, in the open position, a fluid path through the valvechamber 140 is opened and liquid contained within the container 110 mayflow substantially uninhibited from the container 110 and into theuser's mouth through the valve chamber 140.

When the pressure is substantially equalized between inside and outsidethe container 110, the valve flap 180 may be biased by the hinge 190 toreturn to the substantially closed positioned. When the valve flap 180is in the substantially closed position, any liquid in the valve chamber140 may drain back into the container 110 through the drain 200, asillustrated in FIGS. 7 and 15. Furthermore, with the valve flap 180 inthe substantially closed position, any splashing of the liquid withinthe container 110 may be retained substantially inside the container110, as is illustrated in FIGS. 8 and 16. In other words, the valve flap180 in the substantially closed position inhibits splashing liquidinside the container 110 from escaping the container 110.

The lid 120 may be formed from conventional materials. By way of exampleand not limitation, the lid 120 may comprise a plastic material (i.e., apolymer) formed by conventional techniques, such as one or more ofthermal forming (i.e., thermoforming), vacuum forming (i.e.,vacuforming), injection molding, and other forming processes. In atleast some embodiments, the lid 120, including the valve chamber 140,may be formed with the valve flap 180 attached to every side of thevalve chamber 140. The sides of the valve flap 180 where there is nohinge 190 may be cut free from the valve chamber 140 using a punch orother known process, resulting in a hinge 190 where the valve flap 180is not cut free from the valve chamber 140. In view of this, the entirelid 120, including the valve chamber 140 and valve flap 180, may be asingle, monolithic structure.

While certain embodiments have been described and shown in theaccompanying drawings, such embodiments are merely illustrative and notrestrictive of the scope of the invention, and the invention is notlimited to the specific constructions and arrangements shown anddescribed, since various other additions and modifications to, anddeletions from, the described embodiments will be apparent to one ofordinary skill in the art. Thus, the scope of the invention is onlylimited by the literal language, and equivalents, of the claims whichfollow.

What is claimed is:
 1. A lid, comprising: a valve chamber, the valvechamber comprising: a hollow chamber defined by one or more sidewallshaving a first opening at a first longitudinal end and a second openingat an opposing, second longitudinal end; a valve flap positioned atleast proximate to the second longitudinal end, the valve flap having ashape and size substantially the same as or smaller than a shape andsize of the second opening; and a hinge coupling the valve flap to thelid, the hinge sized and configured to enable rotation of the valve flapfrom an open position to a substantially closed position and to bias thevalve flap to the substantially closed position; wherein the lid isshaped and configured to nest with a substantially identical lid withthe valve flap positioned fully within a valve chamber of thesubstantially identical lid and with the lid positioned at a parallelorientation to the substantially identical lid.
 2. The lid of claim 1,wherein the valve flap is configured to inhibit the flow of liquidthrough the second opening in the substantially closed position.
 3. Thelid of claim 1, wherein the valve chamber further comprises a drainpositioned at least proximate to the second longitudinal end, the drainconfigured to flow residual fluid therethrough when the valve flap is inthe substantially closed position.
 4. The lid of claim 3, wherein thevalve flap is angled from the hinge downward between about 1° and about10° relative to a horizontal position when the valve flap is in thesubstantially closed position.
 5. The lid of claim 4, wherein the drainis positioned at a lowest side of the valve flap.
 6. The lid of claim 3,wherein the drain comprises at least one of: a notch formed in the valveflap and a corresponding notch formed in the one or more sidewalls ofthe valve chamber; and a slit-like opening between the valve flap and aportion of the hollow chamber defining the second opening.
 7. A lid fora container assembly, comprising: a channel configured to engage a rimof a container to form a seal between the lid and the rim of thecontainer, and to cover a peripherally outermost surface of the rim ofthe container; and a valve chamber, the valve chamber comprising: ahollow chamber defined by one or more sidewalls having a first openingat a first longitudinal end and a second opening at an opposing, secondlongitudinal end; a valve flap positioned at least proximate to thesecond longitudinal end, the valve flap having a shape and size smallerthan a shape and size of the second opening; and a hinge coupling thevalve flap to the lid, the hinge sized and configured to enable rotationof the valve flap from an open position to a substantially closedposition and to bias the valve flap to the substantially closedposition; wherein the lid is a monolithic structure.
 8. The lid of claim7, wherein the channel is configured to engage a rim of a containerselected from the group consisting of an insulated disposable coffeecup, a non-insulated disposable coffee cup, and a disposable soft-drinkcup.
 9. The lid of claim 7, wherein the one or more sidewalls comprise afirst sidewall and an opposing second sidewall.
 10. The lid of claim 7,wherein the first sidewall has an angle between about 2° and about 20°relative to the opposing second sidewall.
 11. The lid of claim 10,wherein the first sidewall has an angle of about 10° relative to theopposing second sidewall.
 12. The lid of claim 7, wherein the valvechamber comprises a cross-sectional shape selected from the groupconsisting of circular, square, rectangular, and oval.
 13. The lid ofclaim 7, wherein the valve chamber has a height from the first openingto the second opening of between about 3/16 of an inch and about ⅜ of aninch.
 14. A method of forming a lid, comprising: forming a single,monolithic structure, comprising: forming a channel configured to engageand seal around a rim of a container; and forming a valve chambercomprising: a hollow chamber defined by one or more sidewalls having afirst opening at a first longitudinal end and a second opening at anopposing, second longitudinal end; a valve flap positioned at leastproximate to the second longitudinal end, the valve flap having a shapeand size substantially the same as or smaller than a shape and size ofthe second opening; and a hinge coupling the valve flap to the lid, thehinge sized and configured to enable rotation of the valve flap from anopen position to a substantially closed position and to bias the valveflap to the substantially closed position, wherein the lid is formed tonest with a substantially identical lid with the valve flap of the lidpositioned fully within a valve chamber of the substantially identicallid and with the lid positioned at a parallel orientation to thesubstantially identical lid.
 15. The method of claim 14, furthercomprising forming the lid with a thermal vacuum forming process. 16.The method of claim 14, further comprising forming the valve flap bycutting the formed valve chamber.
 17. The method of claim 14, whereinforming a single, monolithic structure comprises forming the lid from aplastic material.
 18. The method of claim 14, wherein the valve flap isformed at an angle relative to horizontal when the lid is orientedhorizontally.
 19. The method of claim 18, wherein the valve flap isformed at an angle of between about 5° and about 7° relative tohorizontal when the lid is oriented horizontally.
 20. The method ofclaim 14, further comprising removing material from the single,monolithic structure proximate the valve flap to form a drain fordraining residual fluid from the valve chamber.